Dealer and Chrysler LLC. can't diagnose problem on 2006 Chrysler 300

We have been dealing with this for over 2 years now and several $1,000 already invested. Nobody can seem to diagnose the problem. The last codes that have come up are P0300 and P0430. Multiple misfire and catalyst efficiency. Every mechanic wants to use a process of elimination due to not understanding the codes. They've already replaced the EGR Valve and the Speed Sensor #2. I thought the whole reason for a diagnostic is to be able to read codes and fix the issue that codes suggest as the problem. I have read tons of horror stories about people that had to have the whole engine replaced. My research shows that it's a good possiblity that the PCM is the issue, but I'm not a mechanic and this is just probable. Any advice from someone familiar with this problem would be appreciated. I have another appointment with the dealership on Wednesday. I have made Chrysler LLC.'s customer service push for an escalation to corporate throught the dealership to try and remedy both the issue and my overwhelming cost. I'll keep the group informed on what transpires from here. Hopefully it'll help someone else with these issues find a way to handle this without all the cost.

Thanks for sharing the story; so sorry you are experiencing this frustration.

Codes set are only clues for a qualified technician to find out what is happening. A P0300 is merely a random misfire code - there is no other help there. It would lead to testing each cylinder compression and power balance the cylinders to determine if there are any weaknesses under load that may show up for plugs or secondary ignition.

P0430 is most likely a catalytic converter issue. This could be due to excessive fuel passing through the exhaust due to a misfire (as stated in P0300), causing the catalyst to get too hot and become damaged.

Monitoring should occur of the oxygen sensors before and after the bank 2 converter (P0430 is bank 2) to see if the catalyst is doing anything at all.

It doesn't seem that complex really. If you had EGR codes and a speed sensor code before, it appears this problem has been solved since the codes have not reoccurred.

Keep in mind that you can always try another dealership for a second opinion. Also keep in mind that if you are under 80,000 miles, you catalyst is likely under warranty anyway! Push for further assistance.

Thank you. Your answer lines up with most of my research. The P0430 is the one code that I had a hard time pinpointing with my research. The P0300 is a common problem with the 2006 Chrysler 300's. There are several TSB's on this issue. I'm listing the information I've found and ask if you may know what kind of complications this might cause on the life of other parts with it gaining 30,000+ miles while having this problem?

The TSB's I have on this year, make and model are:

1) Engine Controls - MIL ON/DTC P0300 SetNUMBER: 18-013-07GROUP: Vehicle PerformanceDATE: February 17, 2007THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET.StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 7.03 OR HIGHER FOR THIS BULLETIN.SUBJECT:Flash: MIL Illumination - DTC P0300 - Multiple Cylinder Misfire (Police Package)OVERVIEW:This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software.MODELS:2006 (LX) 300/Charger/MagnumNOTE :This bulletin applies to models equipped with a 3.5L Engine, W5A580 (NAGI) Automatic Transmission and Police Package (sales code EGG/DGJ and AHB).SYMPTOM/CONDITION:The vehicle operator may experience MIL illumination with no other symptoms or conditions experienced. This condition may occur intermittently and can be difficult to duplicate.

2) Engine, A/T Controls - 1-2 Upshift Shudder/Rough Shift

NUMBER: 21-012-06 REV. B

GROUP Transmission

DATE: October 3, 2006

THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-012-06 REV. A, DATED JUNE 15, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF 3.5L MODELS FOR THE 2006 MODEL YEAR.

THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET.

UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES FOR StarSCAN(R).

StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 7.02 OR HIGHER FOR THIS BULLETIN.

StarMOBILE(R) STANDALONE DOES NOT SUPPORT THIS FLASH RELEASE.

SUBJECT:Flash: 1 - 2 Upshift Shudder or Rough Shift

OVERVIEW:This bulletin involves checking the 2 - 4 Clutch Volume Index (CVI) and if necessary selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software and then performing a Quicklearn to reset the CVI.

MODELS:

2005 - 2006 (LX/LE) 300/Charger/Magnum (Includes International Markets)NOTE :This bulletin applies to all 2005 models with a 2.7L or 3.5L engine and 42RLE transmission (Sales Code EER or EGG with DG6) and 2006 LX models equipped with a 2.7L engine and 42RLE transmission (Sales Code EER and DG6) built prior to April 4, 2006 (MDH0404XX) or 2006 LE models equipped equipped with a 2.7L engine and 42RLE transmission (Sales Code EER and DG6) built prior to April 5, 2006 (MDH04O5XX) ** and all 2006 models equipped with a 3.5L engine and 42RLE transmission (Sales Code EGG with DG6)**.

THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-005-05, DATED DECEMBER 2, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS.

In addition, MIL illumination may also have occurred due to Diagnostic Trouble Code (DTC) P0300 - Multiple Cylinder Misfire. Various single cylinder misfire DTC's may also be present. If the frequency of misfire is high, the Powertrain Control Module (PCM) may place the engine in "Limp-In" mode.

The misfire condition may be caused by one or more engine exhaust valves that are slow to close due to a build up of carbon on the valve stem.

4) NUMBER: 18-016-06

GROUP: Vehicle Performance

DATE: May 4, 2006

THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET.

UPDATE CD 6.05_SP4 WAS THE LAST CD TO CONTAIN FLASH FILES FOR StarSCAN.

OVERVIEW:This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software.

MODELS:

2006 (LX) 300/Charger/MagnumNOTE :This bulletin applies to models equipped with a 3.5L Engine, A580 Automatic Transmission and California Emissions (sales code EGG/DGJ and NAE) built on or before May 2, 2006 (MDH 0502XX).

SYMPTOM/CONDITION:

The vehicle operator may experience MIL illumination with no other symptoms or conditions experienced. This condition may occur intermittently and can be difficult to duplicate.

5) NUMBER: 21-011-06

GROUP: Transmission

DATE: April 19, 2006

THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-019-05 REV. A, DATED NOVEMBER 12,2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN UPDATED NOTE CLARIFYING PARTS TO BE DISCARDED.

Vehicle may experience shudder on slow, parking lot type turns. The friction disc in the transfer case can become clogged with iron particles and may create a stick-slip condition with the pressure plate inside the transfer case.

The condition may be due to the cowl drain flowing water onto the connectors for the 02 sensor(s) at the center rear area of the engine. This leads to water intrusion into the wiring harness connector(s) which may lead to terminal corrosion and/or MIL illumination.

7) NUMBER: 21-014-05

GROUP: Transmission

DATE: August 23, 2005

THE StarSCAN FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THEINTERNET.

THE FLASH FILE WILL BE AVAILABLE ON THE NEXT StarSCAN(R) UPDATE CDRECEIVED AFTER CD 6.02.

SUBJECT:FLASH: Clicking Sound From Rear of Vehicle After Accelerating From A Stop

OVERVIEW:This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software.

MODELS:2005 - 2006 (LX) 300/Magnum

NOTE : This bulletin applies to 2006 vehicles equipped with a 3.5L engine (sales code EGG) and a 42RLE transmission (sales code DG6) built on or before July 29, 2005 (MDH 0729XX) and 2005 vehicles equipped with a 2.7L or 3.5L engine (sales code EER or EGG) and a 42RLE transmission (sales code DG6).

SYMPTOM/CONDITION:The new PCM software corrects a customer complaint of a click sound, coming from the rear of the vehicle, immediately after accelerating the vehicle from a stop. This sound may be verified by driving the vehicle and allowing the transmission to shift into 4th gear then allowing the vehicle to coastdown to a stop, without tipping into the accelerator pedal before the complete stop. The sound will be heard immediately after launching the vehicle and will seem to be coming from the rear of the vehicle.

This is what I have that I'm taking to Chrysler, both dealership and corporate. The sad thing is, my car was at two dealership's service departments. Both ran diagnostics and didn't come back with any insight as to what it may be. This pretty much tells me that they don't use the TSB's at all. I have another appointment at the dealership in 2 days that was pushed through Chrysler customer assistance.

Note: If you have issues that your dealership said they wouldn't cover on models prior to their 2009 bankruptcy. Chrysler has recently stepped up and said that they are now honoring these warranties again. Be nice, but intelligent in how you handle all talks with both corporate and dealership. Have your ducks in a row and be persistant, but nice. Also, do some research. Look at goodwill warrantys or secret warranty's. Line up your problems from when you first started trying to get it fixed. Create a dated pattern of this and throw in TSB's, you'll start to see them willing to work with you. Their all about image right now and are trying to restructure how people look at their brand. You'll have more luck getting things accomplished right now than you did before.

If I can help, let me know. I'll send what I have or put info on this site if their are too many requests.

Good luck to everyone with this year. This is their worst mechanical year for this model, so I know there are others that are confused and think that they'll never find the problem and are stuck with this crappy car. It really is a nice car, they just need to correct some design flaws with sensors.

Boy, you said it. "Be nice, but intelligent..." that's fantastic advice. I can tell you that "nice" gets you MUCH further than "difficult". Intelligent is great - you are using multiple resources to educate yourself, and that makes it possible for you to have a stronger argument.

The biggest "repair" I see in the TSB's you shared is recalibration of the engine processor. The other repair was the decarbonizing of the combustion chamber, and replacement of the MAP sensor. This may be a key item as well.

Keep in mind that your P0430 Catalyst inefficiency code (bank 2) is probably a result of these issues over a long term. As I stated in my original posting:

"P0430 is most likely a catalytic converter issue. This could be due to excessive fuel passing through the exhaust due to a misfire (as stated in P0300), causing the catalyst to get too hot and become damaged. "

I have had the same problems in the past and the present. I'm telling you this replacing the engine will only stop the problem for a couple 1000 miles but trust me it WILL come back. The only thing you can do is replace the ECU and all the computers. That will be the only way to stop all problems. when replacing computers do not buy from dealership buy from factory. It will be cheaper and they test all their products for 100's of hours just to see if they will past the test of the real world. I own a 2007 Chrysler 300C I already replaced one engine not willing to put another 7G's into another one. so ill spend the 2K to replace all my comps. its better and less money you spend.